AIRCRAFT Materials

&
Composites

Lecture by
R B Karthik Aamanchi
Assistant Professor
GITAM University

INTRODUCTION TO COMPOSITES

Classification
Characterization
Advantages and Applications
Reinforcements and Matrices
Composite Structures
Single layer symmetric, Anti-symmetric & un-symmetric
Lay up Configurations

Composites in Aircrafts

The world of materials

Steels
Cast irons
Al-alloys

Metals
Cu-alloys
Ni-alloys
Ti-alloys
PE, PP, PC
PA (Nylon)

Alumina
Si-Carbide

Ceramics,
glasses
Soda-glass
Pyrex

GFRP
CFRP

Polymers,
elastomers
Butyl rubber
Neoprene

Composites
KFRP
Plywood

Polymer foams
Metal foams

Foams
Ceramic foams
Glass foams

Woods

Natural
materials
Natural fibres:
Hemp, Flax,
Cotton

What is Composite????

A Composite material is a material system composed of two

or more macro constituents that differ in shape and chemical
composition and which are insoluble in each other. The
history of composite materials dates back to early 20th
century. In 1940, fiber glass was first used to reinforce epoxy.

Matrix

METAL
CERAMIC
POLYMER

Reinforcement

FIBER
PARTICLE
STRUCTURAL

Composite

Composite Survey
Composites

Particle-reinforced

Largeparticle

Dispersionstrengthened

Fiber-reinforced

Continuous
(aligned)

Structural

Discontinuous
(short)

Aligned

Randomly
oriented

Laminates

Sandwich
panels

Adapted from Fig. 16.2,

Callister 7e.

ADVANTAGES OF COMPOSITES

Composite Benefits
CMCs: Increased toughness
Force

PMCs: Increased E/r

10 3

particle-reinf

E(GPa)
PMCs
2
10
10

fiber-reinf

un-reinf

10 -4

Increased
creep
resistance

ess (s-1)
10 -6
10 -8
10 -10

metal/
metal alloys

.1 G=3E/8 polymers
.01 K=E
.1 .3 1 3 10 30
Density, r [mg/m3]

Bend displacement

MMCs:

ceramics

6061 Al

6061 Al
w/SiC
whiskers

20 30 50

Adapted from T.G. Nieh, "Creep rupture of a

silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp. 139146, 1984. Used with permission.

s(MPa)
100 200

Composite Parameters
For a given matrix/dispersed phase
system:

Concentration
Size
Shape
Distribution
Orientation

Parameters

Distribution

Concentration

Shape

Orientation

Size

MATRIX & ITS TYPES

POLYMER MATRIX:
Polymers are organic chain of molecules which repeat
themselves.
These are structurally complex then metals and ceramics.
These have low strength, low modulus and low operating
temperatures.

Functions of the Matrix Material

(Primary Phase)
Provides the bulk form of the part or product made
of the composite material
Holds the imbedded phase in place, usually enclosing
and often concealing it
When a load is applied, the matrix shares the load
with the secondary phase, in some cases deforming
so that the stress is essentially born by the
reinforcing agent

Metal Matrix Composites (MMCs)

1.
2.

MMCs are made by dispersing a reinforcing material into a metal matrix.

For example, carbon fibers are commonly used in aluminium matrix to
synthesize composites showing low density and high strength. However,
carbon reacts with aluminium to generate a brittle and water-soluble
compoundAl4C3 on the surface of the fiber. To prevent this reaction, the
carbon fibers are coated with nickel or titanium boride.

REINFORCEMENT
Wear Resistance

Friction Co-efficient

CERMETS
Light phase - Matrix (Cobalt)

Thermal Conductivity

FIBERS
isotropic material.

Dark phase- Particulate (WC)

Anistropic give the

strength.

Cermets
MMC with ceramic contained in a metallic matrix
The ceramic often dominates the mixture, sometimes up to
96% by volume
Bonding can be enhanced by slight solubility between phases
at elevated temperatures used in processing
Cermets can be subdivided into
1.
2.

Cemented carbides most common

Oxide-based cermets less common

Cemented Carbides
One or more carbide compounds bonded in a metallic
matrix
The term cermet is not used for all of these
materials, even though it is technically correct
Common cemented carbides are based on tungsten
carbide (WC), titanium carbide (TiC), and chromium
carbide (Cr3C2)
Tantalum carbide (TaC) and others are less common
Metallic binders: usually cobalt (Co) or nickel (Ni)

Figure 9.8 - Photomicrograph (about 1500X) of cemented carbide with

85% WC and 15% Co (photo courtesy of Kennametal Inc.)

Figure 9.9 - Typical plot of hardness and transverse rupture strength as a

function of cobalt content

Applications of Cemented Carbides

Tungsten carbide cermets (Co binder) - cutting tools
are most common; other: wire drawing dies, rock
drilling bits and other mining tools, dies for powder
metallurgy, indenters for hardness testers
Titanium carbide cermets (Ni binder) - high
temperature applications such as gas-turbine nozzle
vanes, valve seats, thermocouple protection tubes,
torch tips, cutting tools for steels
Chromium carbides cermets (Ni binder) - gage blocks,
valve liners, spray nozzles, bearing seal rings

CERAMIC MATRIX
They consist of ceramic fibers embedded in a ceramic matrix,
thus forming a ceramic fiber reinforced ceramic
(CFRC) material. The matrix and fibers can consist of any
ceramic material, whereby carbon and carbon fibers can also
be considered a ceramic material.

Why CMC????
General ceramic materials cannot with stand fracture
under mechanical or thermo-mechanical loads, thus
resulting in crack initiation. To prevent this, CMC
were developed which has higher fracture
toughness. Not only Fracture toughness but other
properties like elongation and thermal shock
resistance also increased drastically.

PROPERTIES OF CMC

Type of material

Al2O3/Al2O3

Al2O3

CVI-C/SiC

LPI-C/SiC

LSI-C/SiC

SiSiC

Porosity (%)

35

<1

12

12

<1

Density (g/cm3)

2.1

3.9

2.1

1.9

1.9

3.1

Tensile
strength (MPa)

65

250

310

250

190

200

Elongation (%)

0.12

0.1

0.75

0.5

0.35

0.05

Young's
modulus (GPa)

50

400

95

65

60

395

Flexural
strength (MPa)

80

450

475

500

300

400

 CMCs usually exhibit Non-linear stress-strain

curves. They behave as if they are deforming
plastically, but they are Quasi-plastic in
nature.
CMCs whose matrix percentage is lower will
have high tensile strength and low bending
strength.
CMCs which have low fiber content, have high
bonding strength but low tensile strength.

Material
Interlaminar shear
strength (MPa)

CVI-C/SiC

LPI-C/SiC

45

LSI-C/SiC

CVI-SiC/SiC

30

33

50

Tensile strength
vertical to fabric plane 6
(MPa)

Compressive strength
vertical to fabric plane 500
(MPa)

450

500

Thermal and Electrical Properties

Material

CVI-C/SiC

LPI-C/SiC

LSI-C/SiC

CVI-SiC/SiC

SiSiC

Thermal conductivity (p)

[W/(mK)]

15

11

21

18

>100

Thermal conductivity (v)

[W/(mK)]

15

10

>100

Linear expansion (p) [1061/K]

1.3

1.2

2.3

Linear expansion (v) [1061/K]

Electrical resistance (p) [cm]

50

Electrical resistance (v) [cm]

0.4

50

APPLICATIONS
Disc brakes/systems
thermal shock
As Heat Shield

Hot gas ducts Oxide CMC

Nozzles of aircraft high
temperature

Side Bearings
Corrosion & wear
Resistance

POLYMER MATRIX
Polymer Matrix Composite (PMC) is the material consisting of
a polymer (resin) matrix combined with a fibrous reinforcing dispersed
phase. Polymer Matrix Composites are very popular due to their low cost
and simple fabrication methods.
Use of non-reinforced polymers as structure materials is limited by low
level of their mechanical properties: tensile strength of one of the
strongest polymers - epoxy resin is 20000 psi (140 MPa). In addition to
relatively low strength, polymer materials possess low impact resistance.

PMC
Thermosets

Thermoplastics

1. These are cross-link Polymers.

1. These are non-cross-link Polymers.

2. These upon heating do not soften.

2. Under heat they become soft and melt.

3. These dont have shelf life more.

3. These have higher shelf-life.

4. These exhibit medium fracture toughness.

5. These are not environmental friendly.

4. These exhibit high fracture toughness and

better resistance to solvent attack.

6. Easy to manufacture and less expensive

5. These are environment benign.

6. Complex manufacturing methods and are
quite expensive.

According to the reinforcement material the following groups of Polymer Matrix

Composites (PMC) are used:
Fiber glasses Glass Fiber Reinforced Polymers;
Carbon Fiber Reinforced Polymer Composites;
Kevlar (aramid) fiber reinforced polymers.
Reinforcing fibers may be arranged in different forms:
Unidirectional fibers;
Rovings;
Veil mat: thin pile of randomly orientated and looped continuous fibers;
Chopped strands: thin pile of randomly orientated and looped short (3-4
inches) fibers;
Woven fabric.
Properties of Polymer Matrix Composites are determined by:
Properties of the fibers;
Orientation of the fibers;
Concentration of the fibers;
Properties of the matrix.

PROPERTIES OF PMC

High tensile strength;

High stiffness;
High Fracture Toughness;
Good abrasion resistance;
Good puncture resistance;
Good corrosion resistance;
Low cost.

DISADVANTAGES:
Low thermal resistance;
High coefficient of thermal expansion.

APPLICATIONS OF PMC

Reinforcements
Continuous

Fibers
Discontinuous

Particles

Flakes

Whiskers

Characteristics of Reinforcement
A small diameter wrt grain size called as SIZE
EFFECT. If diameter of fiber increases, strength
of the fiber decreases.
Higher aspect ratio (L/D) allows large fraction
of load to be transferred via matrix to the stiff
and stronger fiber.
A very high degree of flexibility is necessary.

STRUCTURES - SANDWICH

Sandwich
Composite
Two Thin
Stiff skins
Light weight
thick core

 Materials used for Core

PVC, Polyethylene, polyurethane, Balsa Wood,
honey combs etc
Material used for skins
Thermosets or thermoplastics are used.

CONFIGURATION LAY-UP
Symmetric Laminate:
Laminate is called symmetric when the material, angle and
thickness of the layers are the same above and below the
midplane.

 Anti-Symmetric: [45/-30/30/-45]
A laminate is called antisymmetric when the material and thickness
of the plies are same above and below the midplane but the
orientation of the plies at same distance above and below the
midplane have opposite signs.

Cross-Ply Laminate: [0/90/0/90/0]

A laminate is called cross-ply laminate if all the plies used to
fabricate the laminate are only and 0 and 90.

 Angle Ply Laminate: [45/-45/30/-30]

A laminate is called an angle ply laminate if it has plies of the
same thickness and material and are oriented at +and
- .

Balanced Laminate: [45/30/60/-45/-30/-60]

A laminate is called balanced laminate when it has pairs of plies
with same thickness and material and the angles of plies
are + and - . However, the balanced laminate can also have
layers oriented at 0 and 90.